Install the 1/2 stem lock pin A and the 5th gear stem lock pin B.
Raise the 3/4 hub slightly and install the yoke and 3/4 stem.
Insert the pins into the fork using the tool (B.Vi.949).
Install fifth gear shaft A and reverse shaft B. To do this, slightly raise the input shaft.
Make sure the following are correctly positioned:
- centering bushings;
- magnet;
- shims for bearing preload on JR gearboxes.
Install the 1/2 and 3/4 lock springs and balls into the crankcase and compress them with the tool (B.Vi. 1570).
Apply Loctite 518 to the joint surface.
Set third gear.
Position the crankcase with the control shaft in third gear and install the spring and ball to lock until the fifth gear stem appears.
Squeeze the ball to lock and finish installing the crankcase.
Remove fixture (B.Vi.1570).
Rotate the input shaft to properly install the bearings and tighten the pinch bolt to torque (25 Nm).
Install reverse axle A.
Apply three drops of Loctite Frenbloc to the splines of the constant mesh gear and install with the tool (B.Vi.1175).
Install on the input shaft:
- support ring (larger side to the gear);
- bushing under the gear;
- a fifth gear parasitic gear provided with a synchronizing ring;
- fifth gear hub with spring.
With the help of a core (B.VL31-01) Install the 5th gear fork pin.
Engage first gear with the shift lever, and fifth gear by sliding its fork along the stem.
Tighten the gear bolt and nut to:
- input shaft nut - 25 Nm;
- output shaft bolt - 160 Nm.
Set the transmission to neutral.
Install a new sealing ring.
Install the rear cover and tighten the bolts to 25 Nm.
Reinstall the reverse contactor.
Reinstall the speed sensor for the JH semi-automatic transmission.
Install the clutch shaft seal using the tool (B.Vi.1601) - for JR gearbox.
Install the clutch release slave cylinder and tighten the bolts to 21 Nm.
Install the differential output shaft seal using the tool (B.Vi.945) for JH gearbox and accessories (B.Vi.1058) - for JR gearbox.
JH gearbox
Place the oil-lubricated guard A on the planetary gear and fit the oil-lubricated collar C using tool B.
JR gearbox
Fit safety sleeve A 8 tool (B.Vi.945) on the planetary gear and put on the oiled seal using the tool (B.Vi.1058).